Essentially insoluble heavy metal sulfide slurry for wastewater treatment

ABSTRACT

A product and method for the removal of pollutant heavy metals from aqueous solutions which precludes the end user from storing, handling, feeding and controlling hazardous soluble sulfide materials. The product is a slurry which includes a mixture of a liquid medium and an essentially insoluble salt wherein the salt is the reaction product of heavy metal ions, preferably selected from Mn ++  ions, Fe ++  ions, and Fe +++  ions, and sulfide ions derived from soluble sulfide sources such as sodium sulfide, hydrogen sulfide, and sodium hydrosulfide. Addition of the subject slurry to a wastewater stream will effect the precipitation of heavy metals with lesser equilibrium sulfide ion concentrations than that of the essentially insoluble salt. Solids collected by this method may be returned to subsequent wastewater streams for additional removal of heavy metals by any excess heavy metal sulfide salt.

This is a divisional application of U.S. Ser. No. 10/122,775, filed Apr.15, 2002, U.S. Pat. No. 6,896,817.

FIELD OF THE INVENTION

The present invention is directed to a product and a process forproducing a “pre-made” heavy metal sulfide slurry, which can be used forthe removal of heavy metal pollutants from and the reduction ofhexavalent chromium in wastewater.

BACKGROUND OF THE INVENTION

Various chemical precipitation methods have been employed as one aspectof a complete system for the removal of heavy metal pollutants fromaqueous solutions. Sulfide precipitation is often employed becausesulfide salts may be used to remove heavy metal pollutants such as lead,copper, silver, cadmium, zinc, mercury, and nickel. Sulfides are alsoused as a reducing agent to convert hexavalent chromium to trivalentchromium. There are two basic types of sulfide precipitationprocesses—the soluble sulfide process and the insoluble sulfide process.

By the soluble sulfide process, a soluble sulfide salt such as sodiumsulfide or sodium hydrosulfide is added to a wastewater streamcontaining at least one heavy metal pollutant. The soluble salt quicklydissociates into sodium ions and sulfide ions and the heavy metalpollutant ions rapidly react with the sulfide ions to form a relativelyinsoluble heavy metal salt, which precipitates out of solution. Thereare two common problems associated with the soluble sulfide process.First, the relatively insoluble heavy metal pollutant sulfide salt oftenforms as very fine colloidal particles, which are not easily filtered orotherwise separated from the wastewater stream. Of even greater concernis the formation of odorous and highly toxic hydrogen sulfide gas, whichinvariably results from the high concentration of soluble sulfidespresent in the soluble sulfide process. Thus, the soluble sulfideprocess must be carefully monitored and controlled in order to avoiddiscomfort and harm to the treatment personnel.

Sulfur dioxide and sodium metabisulfite are used for chromium reduction,and again, close pH control is necessary to balance the efficiency ofuse, and the evolution of corrosive and toxic sulfur dioxide gas.

Ferrous sulfate and ferrous chloride are used alone and in conjunctionwith sodium metabisulfite. The same concerns are present with sulfurdioxide gas evolution, and the iron salts generate unacceptable amountsof sludge, which is considered a hazardous waste.

U.S. Pat. No. 3,740,331 represents an early attempt to exploit thebenefits of the soluble sulfide process while avoiding the formation ofhydrogen sulfide gas. A soluble heavy metal salt was added eitherimmediately after or immediately before the addition of the solublesulfide salt to the wastewater stream. The heavy metal of the solubleheavy metal salt was chosen based on its relative equilibrium sulfideion concentration as compared to that of the given pollutant heavymetal. That is, the slightly less insoluble heavy metal ion of thesoluble heavy metal salt was added to the wastewater stream during thesoluble sulfide process to act as a scavenger for excess sulfide therebyavoiding the formation of H₂S.

The insoluble sulfide process is a variation on the chemistry disclosedin the '331 patent. By the insoluble sulfide process, a freshly preparedslurry of an essentially insoluble heavy metal sulfide salt is added toa wastewater stream. Hereagain, the heavy metal of the essentiallyinsoluble heavy metal sulfide salt is chosen based on its relativeequilibrium sulfide ion concentration as compared to that of the givenpollutant heavy metal. Specifically, the essentially insoluble heavymetal sulfide salt must be slightly less insoluble than the heavy metalpollutant salt, which will eventually be formed. Thus, as theessentially insoluble heavy metal sulfide salt dissociates in solution,the heavy metal pollutant salt is formed. The essentially insolubleheavy metal sulfide salt can only further dissociate as the sulfide ionsare consumed in the formation of the heavy metal pollutant salt.Therefore, there is never an excess of sulfide ions such that H₂Sformation is avoided.

U.S. Pat. No. 4,102,784 discloses an insoluble sulfide process, which isconcerned with avoiding the formation of very fine, colloidal particlesof the resultant heavy metal pollutant salt. By the process set forth inthe '784 patent approximately 90% of the insoluble sulfide particlesmust have a diameter of at least 50 microns or more. The '784 patentalso requires that the insoluble sulfide slurry is maintained at a pH ofgreater than 7 in order to avoid H₂S formation. Further, although theslurry disclosed in the '784 patent is formed in the absence ofpollutant heavy metal ions to avoid the production of colloidalparticles such as that patent asserts are formed in accordance with themethod of the '331 patent, discussed above, the slurry of the '784patent is, nevertheless, formed on site at the wastewater treatmentfacility and must be constantly, carefully agitated and temperaturecontrolled prior to addition to the wastewater stream. Because theslurry is formed on-site, it must be maintained and fed to thewastewater stream at a pH of greater than 7 in order to reduce theformation of hydrogen sulfide gas which will form in the presence of anyexcess sulfide ions.

U.S. Pat. No. 4,422,943 discloses an insoluble sulfide process, whichemploys iron pyrite, FeS₂, rather than a ferrous or ferric sulfideslurry. That process requires that the slurry is made on-site at thewastewater treatment facility and is added to the wastewater stream at apH above 7 in order to avoid the formation of H₂S gas, which will formin the presence of any excess sulfide ions.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to a heavy metal sulfideslurry for use in a wastewater treatment process, which includes amixture of a liquid medium, preferably water, and an essentiallyinsoluble salt, which is the reaction product of heavy metal ions andsulfide ions. Preferred heavy metal ions include Mn⁺⁺ ions, Fe⁺⁺ ions,and Fe⁺⁺⁺ ions. Preferably the sulfide ions are derived from hydrogensulfide, sodium sulfide, sodium hydrosulfide, potassium sulfide,potassium hydrosulfide, calcium sulfide, or magnesium sulfide. In onepreferred embodiment the essentially insoluble salt is ferrous sulfide.An important aspect of the invention is the small particle size of theessentially insoluble salt within the slurry. Preferably the salt has aparticle size distribution wherein at least about 50 percent of theparticles have a size of less than about 10 microns; most preferably atleast about 75 percent of the particles have a size of less than about10 microns. It is also preferred that at least about 50 percent of theparticles have a size of less than about 1 micron. The salt comprisesgreater than 2 percent by weight of the slurry.

In another aspect the present invention is directed to a heavy metalsulfide slurry for use in a wastewater treatment process which is madeby a method which includes the steps of: (a) precipitating anessentially insoluble heavy metal sulfide salt from a solutioncomprising a soluble heavy metal salt and a soluble sulfide; (b)separating the salt from the solution, thereby forming a slurry havinggreater than 2% by weight of the salt. Step (b) may be achieved byessentially completely separating the salt from the solution and thendispersing the salt into a liquid medium such that a slurry havinggreater than 2% by weight of the salt is formed or by concentrating thesolution, that is, removing excess solution such that a slurry havinggreater than 2% by weight of the salt is formed. If the former means isemployed preferably the salt is washed subsequent to separation from thesolution, thereby removing residual soluble salts. The step (a) ofprecipitating an essentially insoluble heavy metal sulfide salt may beperformed in one of at least two ways. In one embodiment step (a) isachieved by the substeps of (i) preparing an initial solution of asoluble heavy metal salt; (ii) raising the pH and thereby forming aheavy metal hydroxide; and (iii) adding a soluble sulfide, therebyforming an essentially insoluble heavy metal sulfide salt which is thereaction product of the heavy metal hydroxide and the soluble sulfide.In an alternative embodiment step (a) is achieved by the substeps of (i)preparing an initial solution of a soluble sulfide; and (ii) adding asoluble heavy metal salt, thereby forming an essentially insoluble heavymetal sulfide salt which is the reaction product of the soluble heavymetal salt and the soluble sulfide.

Additionally, the present invention is directed to a method for treatingwastewater which includes the steps of: (a) providing an essentiallyinsoluble heavy metal sulfide slurry which is a mixture of a liquidmedium, preferably water, and an essentially insoluble salt which is thereaction product of heavy metal ions, preferably Mn⁺⁺ ions, Fe⁺⁺ ions,or Fe⁺⁺⁺ ions, and a soluble sulfide, the insoluble salt having aparticle size distribution wherein at least about 50 percent of theparticles have a size of less than 10 microns and the salt is greaterthan 2 percent by weight of the slurry; and (b) adding the slurry to awastewater stream containing at least one heavy metal pollutant.Exemplary pollutants, which may be removed by the present process, areheavy metals such as Zn⁺⁺, Ni⁺⁺, Sn⁺⁺, Co⁺⁺, Pb⁺⁺, Cd⁺⁺, Ag⁺, Bi⁺⁺,Cu⁺⁺, and Hg⁺⁺. Further, hexavalent chromium may be reduced to trivalentchromium by the present process. The slurry may be added to thewastewater stream at a pH in the range of from about 2.5 to about 11.Solids formed by the addition of the slurry to the wastewater stream maybe collected and monitored for color. The collected solids, which areessentially black in color, may be returned to the process and added toa subsequent wastewater stream in order to advantageously employ anyunreacted heavy metal sulfide salt.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is directed to a heavy metal sulfide slurry foruse in a wastewater treatment process, which includes a mixture of aliquid medium, preferably water, and an essentially insoluble salt,which is the reaction product of heavy metal ions and sulfide ions.While ferrous ions (Fe⁺⁺) are preferred, manganese ions (Mn⁺⁺ ions) andferric ions (Fe⁺⁺⁺ ions) may also be employed as the heavy metalcomponent of the essentially insoluble heavy metal sulfide salt of thepresent inventive slurry. Preferably, the salt comprises greater than 2percent by weight of the slurry, the balance comprising water and,optionally, one or more additives, discussed below.

Of particular importance to the present invention is the particle sizedistribution of the essentially insoluble heavy metal salt. At least 50percent of the particles are less than 10 microns in diameter.Preferably, at least 75 percent of the particles are less than 10microns in diameter; and most preferably, all of the particles are lessthan 10 microns in diameters. Furthermore, it is preferred that at least50 percent of the particles are less than 1 micron in diameter. Morepreferably, at least 75 percent of the particles are less than 1 micronin diameter. It is also within the scope of the present invention forall of the particles to be less than 1 micron in diameter.

Small particle size is of particular importance to the present inventionfor a variety of reasons. First, smaller particle size means greatersurface area of the salt is exposed to the wastewater stream for rapidand efficient reaction with the pollutant heavy metal ions. While notwishing to be bound by theory, it is believed that the exceedingly smallparticle size contributes to the efficient reaction of dissociatedsulfide ions with heavy metal pollutant ions and the reduceddissociation of excess sulfide ions.

Second, it is believed that small particle size allows for thepreparation of a manageable slurry having a greater percent by weight ofthe salt than could be achieved if the salt had a larger particle size.That is, although it may be possible to form a slurry having greaterthan 2 percent by weight of a salt having a particle size greater thanthat of the present inventive salt, such slurry would not exhibit theease of handling, specifically pumpability and injectability, of thepresent slurry.

Third, and perhaps most important, it is believed that it is the smallparticle size is one reason the present slurry may be prepared ahead oftime, at a site remote from the final wastewater treatment site. Aslurry containing larger particles must be constantly agitated in orderto keep the large particles in suspension. Thus, all prior art insolublesulfide processes have required preparation on-site at the wastewatertreatment facility immediately prior to addition to wastewater stream.In addition to precluding centralized, remote preparation of theinsoluble sulfide slurry, the requirement that prior art slurries areconstantly agitated also increases the likelihood of air entrapment.Heavy metal sulfide salts are especially vulnerable to oxidation and anyexposure to air will reduce the effectiveness of the slurry. Thus, thepresent inventive slurry is preferably maintained in closed containersduring preparation, storage and shipment. This, in combination with theability of the small particles to remain suspended in the slurry withoutstirring or agitation, limits the exposure of much of the volume of theslurry to oxygen such that the possibility of oxidation is reduced.However, it has been found, unexpectedly, in accordance with the presentinvention that, even given equal opportunities for oxygen exposure,dilute slurries are more greatly effected by oxidation than the presentconcentrated slurry, possibly because exposure of the slurry surface tothe air will only oxidize a small percentage of the more concentratedslurry. Oxidation of particles in a more dilute slurry will have agreater adverse effect.

Thus, all prior insoluble sulfide processes have required that thepersonnel performing the wastewater treatment process must freshlyprepare an insoluble sulfide slurry, including monitoring temperature,pH, and agitation, on-site and then feed the slurry to the wastewaterstream at a tightly controlled pH in order to avoid the formation ofnoxious H₂S gas. That is, the pH must be carefully controlled andmaintained above 7 because of the possibility that excess sulfide saltsmay have been employed in preparing the slurry and, therefore, excesssulfide ions may be present. The present heavy metal sulfide salt slurrycan be prepared at a centralized facility, stored, if necessary, andthen shipped to wastewater treatment facilities for turnkey use in theirtreatment processes.

In addition to the essentially insoluble heavy metal sulfide salt andthe liquid medium, which is preferably water, the present inventiveslurry may also include one or more additives. Such additives mayinclude components that merely enhance the physical characteristics orthe performance of the slurry. Exemplary of this class of additive arethickeners, dispersants, flow enhancers, surfactants, perfumes, andfillers. For example, a polyacrylic acid-based dispersant is preferablyemployed in order to evenly disperse the salt in the liquid medium.Other types of additives may include components that are, themselves,employed in wastewater treatment and which may provide a complementarytreatment to or enhancement of the insoluble sulfide process. Such mayinclude, for example, sodium dimethyldithiocarbamate, calciumdimethyldithiocarbamate, calcium sulfide, calcium polysulfide, sodiumborohydride, sodium sulfite, potassium sulfite, sodium sulfide, sodiumhydrosulfide, sodium metabisulfite, potassium sulfide, potassiumhydrosulfide, potassium metabisulfite, additional iron salts such asferric chloride, ferrous chloride, ferrous sulfate, ferric sulfate,ferric hydroxide, ferrous hydroxide, short chain low molecular weighthigh charge density polymers, quaternary amine polymers, polyquatenaryamine polymers, melamine formaldehyde polymers, aluminum hydroxide,sodium aluminate, sodium hydroxide, caustic potash, calcium hydroxide,magnesium hydroxide, magnesium chloride, manganese chloride, manganesedioxide, calcium chloride, aluminum chlorhydrate, sodium silicate,aluminum chloride, polyaluminum chloride, sodium polyacrylate polymers(anionic, cationic and nonionic), antifoam agents, dispersants, andmethylcellulose-based materials. It should be noted that even though, asis discussed in greater detail below, it is a benefit of the presentinventive slurry that it may be added to a wastewater stream at anacidic pH because of the absence of excess sulfide ions, the presentlist of possible additives includes a variety of soluble sulfide saltswhich will effectively add excess sulfide ions. This is because, inaccordance with the present invention, for wastewater streams having anunusually high concentration of heavy metal pollutant ions the presentinsoluble sulfide process may be advantageously and safely combined withthe prior art soluble sulfide process. That is, the present slurryincluding one or more soluble sulfide salts may be added to such aheavily concentrated wastewater stream, even at an acid pH, and thesulfide ions will be immediately, essentially consumed by the pollutantions prior to the formation of any appreciable amount of hydrogensulfide gas. When all of the sulfide ions from the soluble sulfide salthave been consumed, the present essentially insoluble heavy metalsulfide salt will dissociate in accordance with its equilibrium sulfideion concentration and the remaining heavy metal pollutant ions will beprecipitated without the formation of H₂S.

As discussed above, the preferred heavy metal sulfide salt of thepresent inventive slurry is ferrous sulfide, FeS. Less preferred, butalso within the scope of the present invention are manganese sulfide,MnS, and ferric sulfide, Fe₂S₃. As has been noted in the prior art, anyheavy metal sulfide may be employed to remove from a wastewater streamany heavy metal pollutant ion, which has a lower equilibrium sulfide ionconcentration. Thus, in theory, a variety of heavy metals may be used,but in order to effectively remove the greatest number of differingpollutants, ferrous sulfide is most preferred.

The present heavy metal sulfide slurry is preferably made by a processwhich includes the steps of: (a) precipitating an essentially insolubleheavy metal sulfide salt from a solution comprising a soluble heavymetal salt and a soluble sulfide; and (b) separating the insoluble heavymetal sulfide salt from the solution in order to form a slurrycomprising greater than 2% by weight of the slurry. Step (b) may beachieved by essentially completely separating the salt from thesolution, such as by filtering, and then dispersing the salt into aliquid medium such that a slurry having greater than 2% by weight of thesalt is formed or by concentrating the solution, that is, removingexcess solution such that a slurry having greater than 2% by weight ofthe salt is formed. If the former means is employed preferably the saltis washed subsequent to separation from the solution, thereby removingresidual soluble salts.

If the essentially insoluble heavy metal sulfide salt is ferroussulfide, then a preferred soluble heavy metal salt for use in thisprocess is ferrous chloride, although a variety of other soluble ferroussalts may be employed. Preferably, the sulfide ions are derived fromhydrogen sulfide, sodium sulfide, sodium hydrosulfide, potassiumsulfide, potassium hydrosulfide, calcium sulfide, or magnesium sulfide.

In accordance with the present invention, step (a) may be performed inone of two ways. Preferably, step (a) is achieved by preparing aninitial solution of a soluble heavy metal salt, raising the pH, throughthe addition of, preferably, sodium hydroxide and thereby forming aheavy metal hydroxide, and adding a soluble sulfide, thereby forming anessentially insoluble heavy metal sulfide salt which is the reactionproduct of the heavy metal hydroxide and the soluble sulfide. In analternative embodiment step (a) is achieved by preparing an initialsolution of a soluble sulfide and adding a soluble heavy metal salt,thereby forming an essentially insoluble heavy metal sulfide salt whichis the reaction product of the soluble heavy metal salt and the solublesulfide. After the essentially insoluble heavy metal salt is formed, itis preferably separated from the original solution and washed to removeany residual soluble salts. Then, in order to avoid prolonged exposureto air, the insoluble heavy metal salt is dispersed in a liquid medium.Although water is preferred, other liquids such as organic or polymericsolvents may be employed. Further, as noted above, it is also within thescope of the present invention to concentrate the original solution inwhich the salt was formed rather than separating the salt from thatsolution and then dispersing it in a second liquid medium.

In another aspect the present invention is directed to a method fortreating wastewater, which includes, at least, the step of adding thepresent inventive slurry to a wastewater stream, which includes at leastone heavy metal pollutant. Exemplary pollutants, which may be removed bythe present process, are heavy metals such as Zn⁺⁺, Ni⁺⁺, Sn⁺⁺, Co⁺⁺,Pb⁺⁺, Cd⁺⁺, Ag⁺, Bi⁺⁺, Cu⁺⁺, and Hg⁺⁺, although other heavy metalpollutants, which have an equilibrium sulfide ion concentration lessthan that of the present essentially insoluble heavy metal salt, alsomay be removed by the present inventive wastewater treatment process.Further, hexavalent chromium may be reduced to trivalent chromium by thepresent process.

A unique feature of the present process is that the inventive slurry maybe added to the wastewater stream at a pH in the broad range of fromabout 2.5 to about 11. All other known insoluble sulfide processesrequire addition of the insoluble sulfide slurry to the treatment streamat a pH of greater than 7 in order to avoid the formation of H₂S gas.The present slurry essentially precludes the formation of hydrogensulfide gas even at an acidic pH.

As another aspect of the present invention precipitated heavy metalpollutant sulfide salts formed upon treatment by the present process maybe monitored for color. Generally, such salts will be brown or reddishin color. A black color indicates that excess, unreacted ferrous sulfideis present in the precipitant. Such solids may be returned to subsequentwastewater streams in order to advantageously employ any unreacted heavymetal sulfide salt.

EXAMPLES Example 1

An essentially insoluble ferrous sulfide salt in accordance with thepresent invention was prepared as follows. Two parts of a stock solutionof commercial ferrous chloride, FeCl₂ (approximately 26% FeCl₂) wasdiluted with one part water. Caustic (sodium hydroxide) was then addedin excess to precipitate all of the iron as ferrous hydroxide. Sodiumhydrosulfide was then added to convert the ferrous hydroxide to ferroussulfide. Additional water was added to dilute the soluble salts. Theferrous sulfide was then separated from the solution containing solublesalts by means of a filter press. The ferrous sulfide was then dispersedin water to form a slurry having 6.8% percent by weight ferrous sulfide.At least 75 percent of the ferrous sulfide particles were less than 1micron in diameter. Two percent by weight of a polyacrylic acid-baseddispersant was then added.

Example 2

An essentially insoluble ferrous sulfide salt in accordance with thepresent invention was prepared essentially as set forth in Example 1.However, following separation by means of a filter press from theoriginal solution, the ferrous sulfide was then dispersed in water toform a slurry having 20% by weight ferrous sulfide. At least 75 percentof the iron sulfide particles were less than 1 micron in diameter. Twopercent by weight of a polyacrylic acid-based dispersant was then added.

Example 3

An essentially insoluble ferric sulfide salt in accordance with thepresent invention was prepared as follows. A stock solution ofcommercial ferric chloride, FeCl3 (approximately 30% FeCl3) was diluted2:1 with water. Caustic was then added in excess to precipitate all ofthe iron as ferric hydroxide. Sodium hydrosulfide was then added toconvert the ferric hydroxide to ferric sulfide. Additional water wasadded to dilute the soluble salts. The ferric sulfide was then separatedfrom the solution by means of a filter press. The ferric sulfide wasthen dispersed in water to form a slurry having 6.8% percent by weightferric sulfide. Two percent by weight of a polyacrylic acid-baseddispersant was then added.

Example 4

An essentially insoluble ferrous sulfide salt in accordance with thepresent invention was prepared as follows. A concentrated solution ofsodium hydrosulfide was diluted 10:1 with water. Commercially availableferrous chloride solution diluted 10:1 was added to precipitate the ironas ferrous sulfide. Caustic was added to maintain the pH of the mixtureat or around 11. Additional water was added to dilute the soluble salts.The ferrous sulfide was separated from the solution by means of aBuchner funnel and then washed with water to remove any residual solublesalts. The ferrous sulfide was then dispersed in water to form a slurryhaving about 6.5% percent by weight ferrous sulfide. At least 75 percentof the ferrous sulfide particles were less than 1 micron in diameter.Two percent by weight of a polyacrylic acid-based dispersant was thenadded.

Example 5

The essentially insoluble ferric sulfide salt of Example 3 was used toremove metal ions from a wastewater stream as follows. The wastewaterstream contained 31 mg/l of hexavalent chrome, 13.9 mg/l of nickel, and18.7 mg/l of copper. A 1000 ml sample was taken and approximately 2.04grams of material were added to the jar. The solution was mixed. The pHwas adjusted to 2.08 with 10% sulfuric acid. The contents of the jarwere allowed to mix for two hours. The amount of hexavalent chrome atthat time was found to be 6.9 ppm. The pH of the solution was raised to9.0 with 10% sodium hydroxide. The analysis of a filtered sample showedthe total chrome to be less than 10 ppm. Copper was non-detectable andnickel was 0.48 ppm. No odor was detected at any time during theexperiment. Additional material would be required to reduce thehexavalent chrome to lower levels.

Example 6

The essentially insoluble ferrous sulfide salt of Example 2 was used toremove metal ions from a wastewater stream essentially as set forth inExample 5. Once again, following treatment with the present inventiveferrous sulfide slurry and addition of an anionic flocculent, analysisof the clear supernate by ICP showed non-detect levels of chrome, nickeland copper. As above, this example simulates a typical chrome plater andshows how the present inventive heavy metal sulfide slurry performs.There was no odor detected at any time during the reaction.

Comparative Example 7

A magnesium hydroxide-sodium sulfide blend was used to remove metal ionsfrom a wastewater stream as follows. The wastewater stream contained 31mg/l of hexavalent chrome, 13.9 mg/l of nickel, and 18.7 mg/l of copper.A 1000 ml sample was taken. The pH was adjusted to a pH of 7 in order toprevent gassing of sulfide. Approximately 1.055 grams of the magnesiumhydroxide—sodium sulfide blend was added to the jar. The solution wasmixed and allowed to settle. Analysis of the clear supernate showed 0.02mg/l of hexavalent chrome. Most of the hexavalent chrome had beenconverted to trivalent chrome. In order to get clarity of the solution acoagulant was added at a dosage of 0.1 ml/l. The pH of the solution wasraised with sodium hydroxide to a pH of 9. Again the solution was mixed.Then 3.7 mg/l of anionic flocculant was added. The solution was thenallowed to settle. Analysis of the wastewater by ICP showed the chrome,nickel and copper levels to be non-detect. This example shows a priorart process wherein a blend of sulfide and magnesium hydroxide was usedto remove the heavy metals. There was significant odor associated withthis set of experiments because of the soluble sulfide being used.

Example 8

The essentially insoluble ferrous sulfide salt of Example 2 was used toremove metal ions from a wastewater stream as follows. The wastewaterstream contained 83 mg/l of hexavalent chrome. A 1000 ml sample wastaken and approximately 3.0030 grams of material was added to the jar.The solution was mixed for 10 minutes. Analysis of a filtered solutionshowed no hexavalent chrome remaining. The pH of the solution was raisedusing sodium hydroxide to a pH of 9. The solution mixed and then 5 mg/lof anionic flocculant was added. The solution was allowed to settle.Analysis of the clear supernate by ICP showed the levels of chrome to benon-detect. No odor was detected during the experiment.

Comparative Example 9

A commercially available solution of 30% by weight of sodiummetabisulfite was used to remove metal ions from a wastewater stream asfollows. The wastewater stream contained 83 mg/l of hexavalent chrome. A1000 ml sample was taken and the 30% sodium metabisulfite solution wasfed under pH and ORP control. Approximately 2 ml of the sodiummetabisulfite solution was added. The solution was checked forhexavalent chrome and the result was non-detect. All of the hexavalentchrome had been converted to trivalent. A coagulant was added to improveclarity. The dosage rate was 0.150 ml/l. The pH of the solution wasraised to 9 by the addition of sodium hydroxide. Then 4.0 mg/l of ananionic flocculant was added. The solution was allowed to settle.Analysis of the wastewater by ICP showed chrome levels to be non-detect.However, sulfur dioxide fumes were present during the entire experiment.Most users of SO₂ and sodium metabisulfite must use a fume scrubber toavoid this problem.

Example 10

The precipitated solids from Example 6 were allowed to settle and werecollected on a filter paper. The solids still contained black, unreactedinsoluble iron sulfide. Theses solids were then added to another 1000 mlsample of the same wastewater employed in Example 6. The same procedurewas then followed except no additional insoluble sulfide was added.Initial analysis of the chrome showed 83 ppm. Analysis of a sample ofclear supernate showed the hexavalent chrome level was reduced 66 ppm.This example demonstrates how settled solids containing unused insolublesulfide are available for reuse and can be recycled and used insubsequent waste streams. This can be visually determined by the colorof the solids present: Black solids indicate that there is stillchemical activity available in the solids while increasing shades ofbrown ending in light brown show that the insoluble sulfide has beenused.

Example 11

An aluminum extruder was using sodium metabisulfite to reduce hexavalentchrome. The extruder was having difficulty meeting the desired dischargelimits while processing the necessary amount of wastewater. The extruderchanged to a soluble sulfide precipitant containing sodium sulfide andwas able to process more water, meet their discharge limit, and generateless sludge. The personnel involved liked the performance of the sulfidematerial but did not like the smell associated with its use. Aninsoluble ferrous sulfide slurry made in accordance with Example 1 wasintroduced at the facility, replacing the soluble sulfide product. Theextruder was able to meet their discharge requirements and process therequired amount of wastewater, with the added benefit of not generatingany odor.

Example 12

A manganese sulfide material was made by adding hydrochloric acid tomanganese dioxide and then neutralizing this solution with sodiumhydroxide. Sodium hydrosulfide solution was added to excess to convertthe manganese hydroxide to manganese sulfide. The manganese sulfideslurry was diluted with water and filtered. The manganese sulfide solidswere collected and re-slurried with water, creating a mixture that wasabout 10% by weight manganese sulfide.

Example 13

The essentially insoluble manganese sulfide salt slurry of Example 12was used to remove metal ions from a wastewater stream as follows. Thewastewater stream contained 83 mg/l of hexavalent chrome. A 1000 mlsample was taken and approximately 4.5 grams of material was added tothe jar. The pH was adjusted to around 2 and allowed to mix for twohours. Then the solution was checked for hexavalent chrome. Thehexavalent chrome level was found to be 24 mg/l. The pH of the solutionwas raised with sodium hydroxide to a pH of 9. The solution was mixedand 3.5 mg/l of an anionic flocculent was added. The solution wasallowed to settle. Analysis of the clear supernate by ICP showed chrometo be 24 mg/l. There was no odor detected in this experiment.

Although the present invention has been described in connection with thepreferred embodiments, it is to be understood that modifications andvariations may be utilized without departing from the principles andscope of the invention, as those skilled in the art will readilyunderstand. Accordingly, such modifications may be practiced within thescope of the following claims. Moreover, Applicants hereby disclose allsub-ranges of all ranges disclosed herein. These sub-ranges are alsouseful in carrying out the present invention.

1. A heavy metal sulfide slurry for use in a wastewater treatmentprocess comprising a mixture consisting essentially of a liquid mediumand an essentially insoluble salt comprising the reaction product ofheavy metal ions and sulfide ions, the essentially insoluble salt havinga particle size distribution wherein at least about 50 percent of theparticles have a size of less than 1 micron, and the essentiallyinsoluble salt comprising greater than 2 percent by weight of theslurry, wherein upon addition to a wastewater stream containing at leastone heavy metal pollutant selected from the group consisting of Zn⁺⁺,Ni⁺⁺, Sn⁺⁺, Co⁺⁺, Pb⁺⁺, Cd⁺⁺, Ag⁺, Bi⁺⁺, Cu⁺⁺, and Hg⁺⁺, the slurryreacts with and precipitates the heavy metal pollutant.
 2. A heavy metalsulfide slurry as set forth in claim 1 wherein the heavy metal ions areselected from the group consisting of Mn⁺⁺ ions, Fe⁺⁺ ions, and Fe⁺⁺⁺ions.
 3. A heavy metal sulfide slurry as set forth in claim 1 whereinthe sulfide ions are derived from a at least one selected from the groupconsisting of hydrogen sulfide, sodium sulfide, sodium hydrosulfide,potassium sulfide, potassium hydrosulfide, calcium sulfide, andmagnesium sulfide.
 4. A heavy metal sulfide slurry as set forth in claim1 wherein the essentially insoluble salt comprises ferrous sulfide.
 5. Aheavy metal sulfide slurry as set forth in claim 4 wherein the ferroussulfide salt has a particle size distribution wherein at least about 75percent of the particles have a size of less than about 1 micron.
 6. Aheavy metal sulfide slurry as set forth in claim 5 wherein all of theparticles have a size of less than about 1 micron.
 7. A heavy metalsulfide slurry as set forth in claim 1 wherein the medium compriseswater.
 8. A heavy metal sulfide slurry for use in a wastewater treatmentprocess made by the method comprising the steps of: (a) precipitating anessentially insoluble heavy metal sulfide salt from a solutioncomprising a soluble heavy metal salt and a soluble sulfide, the heavymetal sulfide salt having a particle size distribution wherein at leastabout 50 percent of the particles have a size of less than 1 micron; and(b) separating the salt from the solution so as to form a slurrycomprising greater than 2% by weight of the salt, wherein upon additionto a wastewater stream containing at least one heavy metal pollutantselected from the group consisting of Zn⁺⁺, Ni⁺⁺, Sn⁺⁺, Co⁺⁺, Pb⁺⁺,Cd⁺⁺, Ag⁺⁺, Bi⁺⁺, Cu⁺⁺, and Hg⁺⁺, the slurry reacts with andprecipitates the heavy metal pollutant.
 9. A heavy metal sulfide slurryas set forth in claim 8 wherein the step (b) of separating the salt fromthe solution comprises removing excess solution, thereby forming aslurry comprising greater than 2% by weight of the salt.
 10. A heavymetal sulfide slurry as set forth in claim 8 wherein the step (b) ofseparating the salt from the solution comprises essentially completelyseparating the salt from the solution and dispersing the salt into aliquid medium, thereby forming a slurry comprising greater than 2% byweight of the salt.
 11. A heavy metal sulfide slurry as set forth inclaim 8 wherein the step (a) of precipitating an essentially insolubleheavy metal sulfide salt from a solution comprising a soluble heavymetal salt and a soluble sulfide comprises the steps of: (i) preparingan initial solution comprising a soluble heavy metal salt; (ii) raisingthe pH and thereby forming a heavy metal hydroxide; and (iii) adding asoluble sulfide, thereby forming an essentially insoluble heavy metalsulfide salt comprising the reaction product of the heavy metalhydroxide and the soluble sulfide.
 12. A heavy metal sulfide slurry asset forth in claim 8 wherein the step (a) of precipitating anessentially insoluble heavy metal sulfide salt from a solutioncomprising a soluble heavy metal salt and a soluble sulfide comprisesthe steps of: (i) preparing an initial solution comprising a solublesulfide; and (ii) adding a soluble heavy metal salt, thereby forming anessentially insoluble heavy metal sulfide salt comprising the reactionproduct of the soluble heavy metal salt and the soluble sulfide.
 13. Aheavy metal sulfide slurry as set forth in claim 8 wherein the solubleheavy metal salt is selected from the group consisting of soluble Mn⁺⁺salts, soluble Fe⁺⁺ salts, and soluble Fe⁺⁺⁺ salts.
 14. A heavy metalsulfide slurry as set forth in claim 8 wherein the soluble sulfidecomprises at least one selected from the group consisting of hydrogensulfide, sodium sulfide, sodium hydrosulfide, potassium sulfide,potassium hydrosulfide, calcium sulfide, and magnesium sulfide.
 15. Aheavy metal sulfide slurry as set forth in claim 10 further includingthe step of washing the essentially insoluble heavy metal sulfide saltsubsequent to separation from the solution, thereby removing residualsoluble salts.
 16. A heavy metal sulfide slurry as set forth in claim 8wherein the essentially insoluble heavy metal sulfide salt has aparticle size distribution wherein at least about 75 percent of theparticles have a size of less than about 1 micron.
 17. A heavy metalsulfide slurry as set forth in claim 16 wherein the essentiallyinsoluble heavy metal sulfide salt has a particle size distributionwherein all of the particles have a size of less than about 1 micron.